Phenol-formaldehyde resins esterified with higher unsaturated fatty acids and dimerized rosin



Uni d SW68 Pate Don E. Floyd, Robbinsdale, Minn., assignor to Mills, Inc., a corporation of Delaware No Drawing. Application June 25, 1953, Serial No. 364,201 g 4 Claims. (Cl. 260-19) General The present invention relates to improved oleoresinous coating compositions prepared by esterifying p-t-butylphenol formaldehyde resins with mixtures of unsaturated fatty acids and dimerized rosins.

In the application of David Aelony, Serial No. 324,839, filed December 8, 1952, it has been proposed to esterify phenolic resins with mixtures of unsaturated fatty acids and dibasic acids such as the aliphatic dibasic acids containing from 4-10 carbon atoms. It has also been proposed to use rosin as part of the esterifying acid. It has now been found that certain advantages are attained by the use of a mixture of unsaturated fatty acids and dimerized rosin for esterification of the p-t-butylphenol formaldehyde resins. Some of the advantages obtained are as follows: The reaction mixtures are less complex because of the fewer reactants employed. Dimerized rosin shows little tendency to promote gelation during esterification. Dimen'zed rosin is relatively inexpensive as compared with the aliphatic dibasic acids containing from 410 carbon atoms. Dimerized rosin is relatively non-volatile and is not lost from the reaction mixture. Because of the fewer reactants employed, control of the reaction is simpler and likewise the processing and re covery of unreacted raw materials is simplified.

It is, therefore, an object of the present invention to provide a novel oleoresinous coating composition com prising mixed esters of p-t-butylphenol formaldehyde resins with unsaturated higher fatty acids and dimerized rosin.

The resins employed in the present invention are de rived from p-t-butylphenol and formaldehyde. On an average they contain from 4 to about phenolic groups in the resin molecule. The resins are preferably prepared by the acid catalyzed condensation of p-t-butylphenol and formaldehyde. Suitable acid catalysts include oxalic acid, hydrochloric acid and the like. The resinification reaction may be carried out at atmospheric pressure or under superatmospheric pressure. The time required for condensation varies with the temperature and with the amount and type of catalyst. Resins may be made by carrying out the condensation for from /z7 hours at 160 C. in the presence of oxalic acid. Where a strong catalyst such as HCl is employed, a suitable degree of condensation may be obtained in a shorter period of time, and at a lower temperature. A preferred method of forming these resins involves the reaction of the materials at about 160 C. under pressure. When the reaction is carried out to the extent desired the volatile materials including water as well as any unreacted p-t-butylphenol may be vaporized by merely venting the pressure reaction vessel to the atmosphere. The rapid release of pressure results in a pufling or expanding of the resin which presents the resin in a desirable form for further processing.

Where the resin is prepared by conventional atmospheric pressure reaction, it is desirable to remove volatile materials including water and unreacted p-t-butylphenol F by any suitable method such as by vaporizing this ma- 2,730,511 Patented Jan. 10, 1956 2. terial under a vacuum. For the present invention, however, it is not essential that all of these volatile materials be removed. One of the advantages of the present invention is that the esters prepared from resins containing some unreacted starting materials are still suitable.

In general, the resins obtained are brittle resins of light color. They are insoluble in fatty oils and fatty acids. The resins most suitable for the present invention have a viscosity ranging from approximately 4 to about 20 centistokes in a' 30% solution by weight in dimethyl formamide. This viscosity is determined as follows. A filtered 30% solution by weight of the resin in dimethyl formamide is tested in the Ostwald-Fenske S300 viscosimeter at 30- C. using 10 cc. of solution. The time thus obtained is compared with the time and viscosity of a National Bureau of Standards standard sample oil K5 to determine the viscosity of the 30% solution of the resin in accordance with the formula Viscosity in eentistokes= t where The time of efilux varied from 21-74 seconds with the viscosimeter employed.

The resins above described are esterified with a mixture of unsaturated higher fatty acids containing from 822 carbon atoms and dimerized rosin. The fatty acids employed may be single, isolated fatty acids or mixtures of fatty acids derived from a drying or a semi-drying oil or any selected fraction of the mixed acids of a drying or a semi-drying ,oil, particularly the more highly unsaturated fraction of such mixed acids. Particularly useful are the semi-drying oils such as soybean oil, cottonseed oil, and corn oil. The acids employed for esterification should have an iodine value of from 100-160.

The dimerized rosin is a dibasic acid obtained by polymerizing rosin. Suitable materials of this type are on sale under the trade names Dymerex and Dimer 120 which are sold by Hercules Powder Company and Newport Industries respectively;

The mixed acids employed for esterification should I esterify at least of the total hydroxyl content of thephenolic resin. The range of esterification may run from 50-100%, the preferred range being from -l00%. More than the theoretical amount of acids may be employed during esterification in order to speed up the reaction and the excess later removed by extraction or distillation. Usually there is little advantage in using more than 25% excess acid.

The ratio of fatty acids to dimerized rosin in the esterifying acids may be carried within wide limits, depending on the properties desired in the resin ester. High ratios of dimerized rosin lead to increased film hardness, faster drying and usually to improved alkali-resistance. Unduly high ratios of dimerized rosin tend to produce products of reduced flexibility and durability. It is preferred, therefore, that the dimerized rosin be used at a molecular equivalent value in the range of 15-30% of the total esterifying acid, although valuable products are obtained within the range of 10-50%.

The esterification may be carried out by simply heating the resins with the mixed acids at temperatures within the approximate range of 200275 C. Esterification catalysts in general may be employed, but it is preferred to employ triphenyl phosphite or other phosphite esters as the esterification catalyst. The time required for esterification varies widely depending upon. the conditions.

u 3 Approximately 4-8 hours is usually required for virtually complete esterifi'cati'on at260'CT using the azeotropic method. Reaction temperature, catalyst concentration and reactant ratios.alsoexerLazmaterialetfect onthefgime required forv the. desiredldegree. of; esterification:

Esterification may be conductedby thefusion-method; the azeotropic method" or other appropriate methods; In the. azeotropic. method. carriers other thanrxylol for removingwatenmay benemployed." Esterificationmay-.be conducted-at atmospheric pressure: on at. higher or lower pressure.

Following, esterification it is. usually desirable to re? move volatile materials by subjecting; the: reaction. mix? ture to a vacuum: at. an elevated temperature; The ex-. tent of; removal .of volatile: material} however; is not 1 crit= icaliin the present invention. a

The esters obtained:are valuable. for. the: formulation of varnishes, pigmented..air-dr-y-Z and. baking-enamels; for. can and drumlining s,..insulatingt varnish, pigmented air-dry and baking-,primers masonry paints wall paints-and the like.

Example The reaction mixture consisted" of 162 g. 1 equivalent) of a p-t-butylphenol formaldehyde resin having a viscosity of 6.66 centistokes (determined by the method'de scribed herein), 268g (.95. equivalent) of ahighly unsaturated fraction of soybean oil. acids, 112- g. (.30. equivalent) of a dimerized rosin,.4vg..ofi.triphenyl.phosa phite catalyst and 50ml. of commercial xylol. The mixture was heated'to reflux under a Stark and Dean tube and held at 260 C." for approximatelyrdho'urs; About 17.5 ml. of water was collected duringthisperiod. Then vacuum was gradually applieditot the:systernat 260 C. to removethe xylol and othervolatilematerials including the 25% excess offatty acids. Vacuum was first applied by water aspirator: and then by HyV-aeoilpump' to the full limit ofthe pump. The: reaction productiwasa viscous amber-colored. liquid:having:ani acid number of 1455 and ahydroxyl number. of: 238yindicating :vi'rtually completeesterification.

Asarnpleof. this product was diluted. to 50% solids withlmineral spiritsand.-.solub'le drierss'were a'clded' at: a concentration of-"0.-3:%- l'ead:and 0.06% cobalt" (as naphthenates). The:viscosity; ontthe' Gardner-Holdt'seale was A and the. color. by Gardner; .(19339standards) was- 9--l0l Coatings .were appliedxto. glass;plates with a 1 .5 mil blade andlto inverted: testltuh'es'by dipping: The=product dried to the no-transfer stage in 85 mirrutesgtdriedi to a' very slightztack in. 145; minutes,:. andlwass' tacksfree to foil'in 4 hours;

After one: day of: drying; the: coating had: a": hardness valuei of1'34 as; determinedillwtheeswardi Rocker method; andiafterrfonr days :the-rvaluertwas540. Themesistance to 5% aqueous. sodiumzhydroxide-"at C. wasfound. to: be at least 33.6 hours.

' folIowiiig ingredients overnight in a ball'milll Formula: Parts by weight Titanium oxide Lithopone 150 Zinc oxide 50 Lecithin .l 4 Phenolic resin ester; -a 385 Mineral spirits 255 6% manganese. naphthenate 3 Films of the primer' were applied to bonderized steel panels by spraying. The'filmswere. baked. at 400 F. for 20 minutes. They were testedfor resistance to detergents, simulating conditions found in washing machines for home laundry use by immersing the panels in a 1% solution of a commercial home detergent, held at a temperature of F. After 560 hours of immersion the coating was found to-be in better condition thana similar coating of'a high gradecommercialprimertested in the same manner.

I-claim as my invention:

11 A p-t-butylphenolformaldehyde resin esterified with amixture of. an unsaturated higher fatty acid. and dir'neri'zed rosin,.the.resin.being esterified at least 50% and'the dimerizedrosinconstituting from 10-50 equivalent percent of theacids' esterified;

2. A.p.-t-butyl'phenolformaldehyde resin esterified with a mixture of an unsaturated higher fatty acid and dimeri'zed" rosin, the. resin being esteriiied at least 50% andlthe dimerizedQrosin constituting from l5 30 equivalent percent'of the acids esterified.

3'; A p-t-butylphenol formaldehyde. resinesterifiedwith a mixture of an unsaturated higher fatty acid and dimerized rosin, the resin beingesterifi'ed at least 70% and the dimeri'zed rosin. constituting. from 10-50 equivalent percentofthe acids esterifiedI 4. A p-t-butylphenol' formaldehyde resin esterilied witha mixture of an unsaturated higher fatty acid and dimerized' rosin, the resinbeing esterifiedf at least 70% and'the di'merized"rosinconstituting from 10-50 equiva? lent percent of. the acidsesterified, .theproduct being substantiallyfree from materials vaporizable at 260 C. under a high vacuum.

References Citedin the file of this patent UNITED- STATES PATENTS Harrison Dec. 16, 1952 Wheeler May 12, 19-53 OTHER REFERENCES Paint'M'anufacture luly1943; pages 161 and 162. 

1. A P-T-BUTYLPHENOL FORMALDEHYDE RESIN ESTERFIED WITH A MIXTURE OF AN UNSATURATED HIGHER FATTY ACID AND DIMERIZED ROSIN, THE RESIN BEING ESTERIFIED AT LEAST 50% AND THE DIMERIZED ROSIN CONSTITUTING FROM 10-50 EQUIVALENT PERCENT OF THE ACIDS ESTERIFIED. 